SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device -------------------------------------------------------------------------------------------------- 2-1

Group 2 Main Control Valve ---------------------------------------------------------------------------------------- 2-9
Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-31
Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-41
Group 5 RCV Lever ------------------------------------------------------------------------------------------------------ 2-50
 SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 HYDRAULIC PUMP

1. GENERAL
This is a variable displacement double-piston pump for discharge with equal displacements from one
cylinder block. This pump is so compact as to appear a single pump though this is actually a double
pump.
Because this pump has one swash plate, the tilting angle is the same for two pumps. Tilting of the
pump changes in response to the total pressure of P1 + P2. Namely, the output is controlled to the
constant value so that the relationship between the discharge pressure and flow rate Q becomes
constant, (P1 + P2)×Q =Constant.
The third pump and pilot pump can be connected to the same shaft via a coupling.

A1 A2
A1G A2G A3G PPG
R1 A1 A2 A3 A4

ENG

S1

PPG Hydraulic circuit

R1 A3 A1G A2G

A4 A3G S1
555C92MP01

Description of the ports

Port Name Bore
S1 Suction port SAE 1 1/2 (standard)
A1, A2 Discharge port PF 1/2
A3 Discharge port PF 1/2
A4 Discharge port PF 1/4
A1G, A2G Gauge port PF 1/4 With quick coupler
A3G Gauge port PF 1/8 With quick coupler
A4G Gauge port PF 1/4 With quick coupler
R1 Air bleeder port M10×1.0 (with bleeder valve)

2-1
2. PRINCIPAL COMPONENTS AND FUNCTIONS

1 2 5 8

3 6 4 7 R5572SF02

1 Drive shaft 5 Control spring

2 Hanger 6 Control piston
3 Rotary group 7 Gear pump
4 Cover 8 Housing

SPECIFICATIONS
● Capacity : 2×27.5+18.3+4.5 cc/rev
● Rated oil flow : 2×57.8+38.4+9.5 ℓ/min
● Rated pressure : 3×220+30 kgf/cm2

This is a variable displacement double-piston pump for discharge with two equal displacements
from one cylinder block. Because this is one rotary group, there is only one suction port.
The oil is divided into two equal flows by the control plate in the cover and directed to two
discharge ports provided in the cover.
The discharge pressure directed to the control piston tilts the hanger by overcoming the spring
force.
Since the piston stroke changes according to the tilting angle of the hanger, the flow can be
changed.
The simultaneous tilting angle constant-output control method is employed.
The third pump and pilot pump can be connected to the same shaft via a coupling.

2-2
1) PRINCIPLE OF OPERATION
(1) Function of pump

Piston ɷ
Lower dead point
Hanger
Cylinder block (Swash plate)

Control plate
Discharge port

P1

P2

Upper dead point

Discharge
process

Suction process

Suction port

R5572SF03

The cylinder block is connected via spline and can rotate together with the drive shaft.
The piston assembled into the cylinder block performs reciprocal operation while following the
swash plate on the hanger.
The piston moves in a direction to increase the displacement during a stroke from the lower to the
upper dead points. The oil flows from the suction port via a port plate into the cylinder block
(suction process).
During a stroke from the upper to the lower dead points, the piston moves in a direction to
decrease the displacement. The oil is discharged to the discharge port (discharge process).
The displacement can be changed by changing the tilting of the hanger (swash plate).
The oil sucked through the port in the cylinder block is discharged from the discharge port in the
port plate.
The oil sucked through the port on the outside of the cylinder block is discharged from the
discharge port on the outside of the port plate.

2-3
2) CONTROL FUNCTIONS

Spring A Spring B

Hanger D D
Piston
P

A+B P1
pressure

Piston P3
Total

A
Piston
for P3 shift
Shifting line

Piston
Pi
Q max P2
Flow rate
Section D-D
R5572SF04

The discharge pressures P1 and P2 are directed to the pistons of equal area act on the hanger.
The spring is provided to act against the discharge pressure. When the oil pressure acting on the
piston is less than the installation load of the spring A (outer spring), the hanger is fixed to the
maximum tilting position. When the oil, pressure acting on the piston exceeds the installation load
of the spring A the hanger is tilted and kept tilted at a position where the oil pressure is balanced
with the spring force. (region A in the middle of the figure above)
When the oil pressure acting on the piston rises further to reduce the tilting angle, the spring B
which has been inactive up to now becomes active.
To overcome the spring force of two springs, the oil pressure must be higher and the shifting line
becomes more steep. (regions A + B in the middle of the figure above)
When the P3 oil pressure acts on the shift piston, the control shifting line is shifted.

2-4
3) CONTROL / ADJUSTMENT PROCEDURE
(1) Loosen the hexagonal nut.
(2) Tighten or loosen the adjusting screw to set the power shifting line.

Spring seat Cover

Adjusting screw

Tighten

Total pressure
P (P1+P2)
Loosen

Nut
Q max
Flow rate
Tighten Loosen
R5572SF05

2-5
3. ADJUSTMENT
This hydraulic pump has been set and inspected according to your specified input power and control.
Readjustment of all the adjusting portions may lead to the loss of functions specified for each control
and the pump proper may be excluded from the scope of guarantee. Never attempt operating the
adjusting screw, etc.

4. INSTALLATION
(1) Install the pump so that the input shaft becomes horizontal.
(2) Install the pump in a position lower than the lowest oil level in the tank to allow continuous flow of
the oil into the pump.
(3) Since the pump is installed directly to the diesel engine, always use a flexible hose. Install the
suction pipe firmly to prevent suction of an air.
(4) Use the high-pressure type flexible hoses for the discharge ports P1 and P2.
(5) After installation, fill the pump housing with the hydraulic oil.
(6) Do not direct the external drain piping from within the oil.

5. DRIVE
(1) Use a flexible coupling for connection to the motor.
(2) Insert the coupling firmly onto the input shaft. Do not hammer the coupling during insertion.
(3) The input shaft must rotate clockwise when viewed from the shaft end.

6. HYDRAULIC OIL
The hydraulic oil to be used must be a general petroleum, hydraulic oil or wear-resistant hydraulic oil
(ISO 3448, VG 32 ~ 56 or equivalent).
The applicable viscosity range is as follows :
Maximum allowable viscosity : 1000 mm2/s
Minimum allowable viscosity : 10 mm2/s
Recommended viscosity range : 15 ~ 150 mm2/s

7. STARTING PROCEDURE
ö
Before start up, check the following points and observe the cautions :
(1) Check if the tank has been washed clean.
(2) Check if the piping is clean and installed in such a manner as to prevent stress on the pump.
(3) Check if the piping is connected correctly according to the piping (circuit) diagram.
(4) Check if the joint and flange are correctly tightened.
(5) Check if the joint between the motor and pump is correctly installed.
(6) Check if the motor rotation direction agrees with the pump rotation direction.
(7) Check if the specific hydraulic oil is supplied though the filter and filled in the tank to the specified
position of the oil level gage.
(8) Check if the filter has the specified filtration accuracy (10 ˿ or less).
(9) Check if the filter has been installed correctly relative to the float direction.
(10) Check if the pump housing is filled with oil.
(11) Check if the control valve is set to the bypass position.
(12) Start the motor. If necessary, carry out warm-up operation at low speed.
(13) Check, without any load on the system, if the actuator operates correctly.

2-6
 (14) When the motor has reached the operation speed, check the operation while applying the load to
the actuator.
(15) Check the monitoring or measuring instrument if installed.
(16) Check the noise level.
(17) Check the oil level in the tank. Supply the oil. If required.
(18) Check the setting of the pressure control valve while applying the load to the actuator.
(19) Check the parts for any leakage.
(20) Stop the motor.
(21) Retighten all the bolts and plugs even when they have proved to by free from Leakage.
(Be sure to remove the pressure from the circuit before retightening.)
(22) Check the oil level in the tank.
(23) Check if the pump and actuator function correctly.
(24) Irregular operation of the actuator indicates that an air is left still in the circuit. When the air is
bleeded completely from the circuit, all the parts operates smoothly without any irregular
movement and there is no bubble in the oil of the tank.
(25) Check the oil temperature.
(26) Stop the motor.
(27) Check the filter if the element is fouled.
(28) If the element is heavily fouled, carry out flashing in the circuit.
ö To prevent damage to the pump, be sure to observe the following cautions during the operation
which may allow entry of the actuator, hydraulic oil change, etc :
(1) After oil supply, fill the pump housing with the hydraulic oil.
(2) Start the pump with the speed of 1000 rpm or less and take care not to allow the oil level to lower
below the specified level of the oil level gauge.
(3) When bleeding an air from the hydraulic circuit, keep the motor speed at 1000 rpm or less.
Operate each actuator for three or more cycles and carry out idling for 5 minutes or more.
8. MAINTENANCE
The maintenance of this hydraulic pump is limited mainly to the tank, in particular, the hydraulic oil
change.
Since the maintenance interval varies depending on respective operation and use conditions, the
cautions described below for the users should be for reference only.
(1) Checking the filter
Η
Every day for the initial period after start up.
Θ
Once a week when the operation becomes stable.
Ι Once a month when the operation hours exceed about 100 hours.

ö When any part of the hydraulic system is changed (e.g., assembling of an additional part, change
and repair of the piping), check the filter newly as in the case of startup.
(2) Changing the filter
Η
After startup
Θ
After 500 hours of operation
Ι Every 500 hours of operation after that, and each time the hydraulic oil is changed or the failure
occurs. If any abnormal fouling of the filter is observed during daily check up to the first filter
change after startup, find out the cause.
In this case, do not extend the check and filter change intervals to 500 hours.
ö The paper filter can not be cleaned. Change the filter as a whole.

2-7
(3) Changing the hydraulic oil
Η
After 2000 hours of operation.
Θ Every 2000 hours of operation or once a year after that.

The change interval may have to be shortened depending on the degree of fouling and the
thermal load condition of the hydraulic oil.
If the hydraulic oil is not appropriate and need be changed, pay attention to the following points :
Be sure to control the oil temperature below the highest temperature and above the lowest

temperature during operation in winter and summer.

Pay attention to the following points during change of the hydraulic oil :
- Change the hydraulic oil as a whole quantity.
- Do not allow dust to mix into the circuit.
- Clean the tank inside.
- Supply the oil through the filter.
(4) Checking for the oil leakage
Η
Daily during the initial period after startup.
Θ Once a week when the operation becomes stable.

(5) Checking the temperature

Η
Monitor the temperature continuously.
Θ When the viscosity is above the allowable value because of low hydraulic oil temperature,
warm-up operation is necessary.
Start the motor with the speed set to about one half of the rated speed, then operate the actuator
under the load for a short period.
When the oil temperature is below the allowable ambient temperature, it is necessary to preheat
the oil tank before start of the motor.
Take care not to allow the hydraulic oil temperature to exceed +90˚C

2-8
 GROUP 2 MAIN CONTROL VALVE

1. OUTLINE a9
xb9
MR1 a8
a3 a4 a6 a10
a1 a2 sa a5 a7 Gauge a11

Ai Pp

T1 A9
A1 A2 A3 A4 A5 A6 A7 A8 A10 A11

B8
B1 B2 P3 B3 B4 B5 B6 B7 B9 B10 B11
P2 P1

pp2

b1 b2 sb b3 b4 b5 b6 b7 b8 b9 b10 b11
MR3

555C92MC01

Port Tightening Port Tightening

Mark Port name Mark Port name
size torque size torque
P1 P1 pump port B10 Bucket in port
PF 6.0~7.0
P2 P2 pump port B11 Arm 2 port
1/2 kgfÂm
P3 P3 pump port T2 Tank return port
A1 Swing port (LH) T1 Tank return port PF1 10~12 kgfÂm
B1 Swing port (RH) a1 Swing pilot port (LH)
A2 Dozer down port b1 Swing pilot port (RH)
B2 Dozer up port a2 Dozer down pilot port
A3 Woodgrab rotate port (LH) b2 Dozer up pilot port
B3 Woodgrab rotate port (RH) a3 Woodgrab rotate pilot port (LH)
A4 Woodgrab close port b3 Woodgrab rotate pilot port (RH)
B4 Woodgrab open port PF a4 Woodgrab open pilot port
A5 Boom 2 port 1/2 6.0~7.0 b4 Woodgrab close pilot port
B5 Breaker port kgfÂm a5 Boom 2 pilot port PF
A6 Arm out port b5 Breaker pilot port 1/4 2.5~3.0
B6 Arm in port a6 Arm out pilot port kgfÂm
A7 Travel port [LH/FW] b6 Arm in pilot port
B7 Travel port [LH/RR] a9 Boom up pilot port
A8 Travel port [RH/FW] b9 Boom down pilot port
B8 Travel port [RH/RR] a10 Bucket out pilot port
A9 Boom up port b10 Bucket in pilot port
B9 Boom down port a11 Arm 2 pilot port
A10 Bucket out port b11 Arm 2 pilot port
MR1
Main relief valve - PP2 Bucket load check pilot port PF1/8
MR2

2-9
2. STRUCTURE (1/4)

5-4
5-3
5-11 5-2 5-5
5-10 5-6
TI
ON 5-9
OP 5-8 4-4
AB
DG
R 5-1 4-10 4-3
OO 4-11 4-5
W 4-2 4-6
5-12 4-9 3-4
5-11 4-8
3-11 3-3 3-5
3-10 3-6
5-3 5-13 3-9 2-3
5-7 3-8 3-2
5-6 4-1 2-7
5-5 2-5
2-10
2-6
3-13 2-9
3-12
4-3 2-8
4-7 2-2
4-6
4-5 3-1 2-11 2-12
3-3 3-14
3-7
3-6
3-5 2-1
2-13
2-7 2-14 1
2-4
2-6 17
2-5 18
555C92MC02

1 Cover 3-4 Pilot cap (A) 4-9 Check spring

2 Swing block 3-5 Wrench bolt 4-10 Plug
2-1 Block 3-6 Plain washer 4-11 Main relief valve
2-2 Swing spool assy 3-7 Cap 5 Swing block
2-3 Pilot cap (A) 3-8 Check poppet 5-1 Block
2-4 Pilot cap (B1) 3-9 Check spring 5-2 Swing spool assy
2-5 Wrench bolt 3-10 Plug 5-3 O-ring
2-6 Plain washer 3-11 Plug 5-4 Pilot cap (A)
2-7 O-ring 3-12 Check valve 5-5 Wrench bolt
2-8 Check poppet 3-13 O-ring 5-6 Plain washer
2-9 Check spring 3-14 O-ring 5-7 Pilot cap (B1)
2-10 Plug 4 Inlet block 5-8 Check poppet
2-11 Plug 4-1 Block 5-9 Check spring
2-12 O-ring 4-2 Inlet spool assy 5-10 Plug
2-13 O-ring 4-3 O-ring 5-11 Overload relief valve
2-14 Plug 4-4 Pilot cap (A) 5-12 O-ring
3 Dozer block 4-5 Wrench bolt 5-13 O-ring
3-1 Block 4-6 Plain washer 17 Tie bolt
3-2 Dozer spool assy 4-7 Pilot cap (B1) 18 Nut
3-3 O-ring 4-8 Check poppet

2-10
 STRUCTURE (2/4)

9-4
9-3 9-5
9-10 9-6
9-15 9-9 9-2
9-14 8-4
9-8
8-3 8-5
8-10 8-11 8-6
9-1 8-13 8-9
8-8 7-4 TI
ON
9-11 OP
B
7-3 RA
8-2 7-5 DG
7-11 7-6 WOO
9-3 9-13 9-12 7-10
9-7 8-11 7-9 6-4
9-6 7-8
9-5 7-2 6-3
7-1
6-11 6-5
8-1 8-14 6-10 6-6
8-12 7-13 6-9
8-3
8-7 7-12 6-8
8-6 6-2
8-5
7-3 7-14
7-7 6-11
7-6
7-5
6-1
6-13 6-12
6-3
6-7
6-6
6-5

555C92MC03

6 Woodgrab block 7-6 Plain washer 8-11 Overload relief valve

6-1 Block 7-7 Pilot cap (B1) 8-12 O-ring
6-2 Woodgrab spool assy 7-8 Check poppet 8-13 Check valve
6-3 O-ring 7-9 Check spring 8-14 O-ring
6-4 Pilot cap (A) 7-10 Plug 9 Travel block
6-5 Wrench bolt 7-11 Overload relief valve 9-1 Block
6-6 Plain washer 7-12 Plug 9-2 Travel spool assy
6-7 Pilot cap (B1) 7-13 O-ring 9-3 O-ring
6-8 Check poppet 7-14 O-ring 9-4 Pilot cap (A)
6-9 Check spring 8 Arm 1 block 9-5 Wrench bolt
6-10 Plug 8-1 Block 9-6 Plain washer
6-11 Overload relief valve 8-2 Arm 1 spool assy 9-7 Pilot cap (B1)
6-12 O-ring 8-3 O-ring 9-8 Check poppet
6-13 O-ring 8-4 Pilot cap (A) 9-9 Check spring
7 Boom 2 block 8-5 Wrench bolt 9-10 Plug
7-1 Block 8-6 Plain washer 9-11 Plug
7-2 Boom 2 spool assy 8-7 Pilot cap (B1) 9-12 O-ring
7-3 O-ring 8-8 Check poppet 9-13 O-ring
7-4 Pilot cap (A1) 8-9 Check spring 9-14 Poppet
7-5 Wrench bolt 8-10 Plug 9-15 Spring seat

2-11
 STRUCTURE (3/4)
*-12(KIT)

12-15 12-11
12-25 12-13
12-21 12-20
12-29
12-30
12-22
12-28
12-14
12-34
12-27
12-16
12-17
12-26
12-18 12-31
12-24
12-19 12-32
12-4
12-3 12-5
12-10 12-2 12-6
12-9
12-37 12-8
12-7 11-4
11-3
11-5
11-10 11-2 11-6
11-9 10-8
12-33 11-8 10-9
10-12
10-3
10-11
12-1 12-36 12-35 11-1310-6 10-15 10-10
11-1 10-14 10-2
11-11
10-13 10-16
10-17
11-15
11-16
11-12
11-3 11-14 10-18
11-7
11-6 10-5
11-5
10-21
10-4 10-1 10-18
10-20 10-19
10-7
10-8 555C92MC04

10 Inlet block 10-19 O-ring 11-16 O-ring 12-19 Plug

10-1 Block 10-20 O-ring 12 Boom 1 block 12-20 Spring
10-2 Travel straight spool assy 10-21 Plug 12-1 Block 12-21 Steel ball
10-3 O-ring 11 Travel block 12-2 Boom 1 spool assy 12-22 Pilot cover
10-4 O-ring 11-1 Block 12-3 O-ring 12-24 O-ring
10-5 Main relief valve 11-2 Travel spool assy 12-4 Pilot cap (A) 12-25 O-ring
10-6 Plug 3 11-3 O-ring 12-5 Wrench bolt 12-26 Spring
10-7 Pilot cap (B3) 11-4 Pilot cap (A) 12-6 Plain washer 12-27 O-ring
10-8 Wrench bolt 11-5 Wrench bolt 12-7 Check poppet 12-28 Spring seat
10-9 Plain washer 11-6 Plain washer 12-8 Check spring 12-29 Snap ring
10-10 Spring seat 11-7 Pilot cap (B1) 12-9 Plug 12-30 Resistor
10-11 Pilot spring 11-8 Check poppet 12-10 Overload relief valve 12-31 Plain washer
10-12 Pilot cap (B2) 11-9 Check spring 12-11 O-ring 12-32 Wrench bolt
10-13 Check poppet 11-10 Plug 12-13 Holding poppet 12-33 O-ring
10-14 Check spring 11-11 Overload relief valve 12-14 Pilot poppet 12-34 O-ring
10-15 Plug 11-12 Set screw 12-15 Plug 12-35 O-ring
10-16 Plug 11-13 O-ring 12-16 Piston guide 12-36 O-ring
10-17 Spring shim 11-14 O-ring 12-17 Piston 12-37 Socket bolt
10-18 O-ring 11-15 O-ring 12-18 Pilot piston

2-12
 STRUCTURE (4/4)

14-4
14-3 14-5
14-6
18 14-2
16 14-8 14-9

15 13-11 13-5
13-6
13-13 13-10
14-10 13-313-4
13-9
13-8
13-2
14-1
14-3 14-11
14-7 13-11
14-6
14-5

13-1
13-14 13-12
13-3
13-7
13-6
13-5

555C92MC05

13 Bucket block 13-10 Plug 14-5 Wrench bolt

13-1 Block 13-11 Relief valve 14-6 Plain washer
13-2 Bucket spool assy 13-12 O-ring 14-7 Pilot cap (B1)
13-3 O-ring 13-13 Check valve 14-8 Plug
13-4 Pilot cap (A) 13-14 O-ring 14-9 Plug
13-5 Wrench bolt 14 Arm 2 block 14-10 Plug
13-6 Plain washer 14-1 Block 14-11 O-ring
13-7 Pilot cap (B1) 14-2 Arm 2 assy 15 Cover
13-8 Check poppet 14-3 O-ring 16 Tie bolt
13-9 Check spring 14-4 Pilot cap (A) 18 Nut

2-13
3. HYDRAULIC CIRCUIT

Pp
PS
AI

a1
b1
B1
Swing

A1

a2
b2
B2
Dozer

P3 A2

b6
Sa
Sb
b4

T1
A3

Woodgrab swing
B3
b3

a3
A4

Woodgrab
A5 b4 B4

a4

b5
Boom 2
Breaker
B5

a5
b5

Dr
A6

Arm 1
b6 B6

a6

b7
A7

Travel
(LH)
B7

a7

Gauge
P2
P1

Check
CHECK
poppet
POPPET
a8
B8

Travel
A8

(RH)
b8
b9

a9
B9

Boom 1
A9

pp2
Dr
xb9

a10
b10
B10

Bucket
A10

a11
b11

Arm 2
T2
5592MC02

2-14
 4. FUNCTION
1) CONTROL IN NEUTRAL FUNCTION

Pp
AI

T1
P3
T1
T

T
P2

Gauge
GAUGE
P1
T

T2 T2

555C92MC07

In neutral, spring sets the spool at the neutral position, the hydraulic oil from pumps flows to the
tank through the center bypass.

2-15
(1) P1
The oil discharged from the hydraulic pump flows into control valve P1 port, and then flows the
right side travel valve through the travel straight valve. In neutral, the oil flows through the center
bypass passage in the direction of right travel → boom 1 → bucket → arm 2 spool, and then
flows from the center bypass passage to the tank port T1 and T2.

(2) P2
The oil discharged from the hydraulic pump flows into control valve P2 port, and then flows the left
side travel valve through the travel straight valve. In neutral, the oil flows through the center
bypass passage in the direction of left travel → arm 1 → boom 2/breaker spool, and then flows
from the center bypass passage to the tank port T1 and T2.

(3) P3
The oil discharged from the hydraulic pump flows into control valve P3.
In neutral, the oil flows through the center bypass passage in the direction of swing → dozer
spool, and then flows from the center bypass passage to the tank port T1 and T2.

(4) Pp
When Pp port is applied with pilot pressure, the oil flows into the swing block through TS signal
passage and Ai signal passage independently via an orifice.
With the spool in neutral, the oil flows into the tank passage through the all section of the control
valve(except arm 2 section). As a result, the TS valve is not shifted and the auto idle signal
pressure is not raised.

2-16
2) EACH SPOOL OPERATION
(1) Travel operation (forward / backward)

B A

ARM1
Arm 1
T Breaker
BREAKER
Center bypass passage TS Ai
Tank
TANK

T
Check poppet
P2

Gauge
GAUGE
P1
T

Boom
BOOM⇒ bucket
BUCKET
⇒ Arm 2
ARM1
B A

T
555C92MC08

· During travel (forward/backward) operation, the pilot pressure from RCV is supplied into the travel
pilot port and shift the travel spool in the right direction.
· The hydraulic oil fluid from pump is entered center bypass passage of inlet block (P1, P2) and
then flows into the port of travel motor.
· The oil from the port A of travel motor flows into the main control valve and return to the hydraulic
oil tank through the tank passage.
· The TS signal passage is shut off by shifting of the travel spool, but it is connected with Ai signal
passage and drain to the hydraulic oil tank. As a result, the travel straight spool is not shifted.
· The Ai signal passage is connected with travel block through swing and dozer block and it is shut
off by shifting of the travel spool and then signal pressure of auto idle is raised.

2-17
(2) Boom operation
① Boom up operation (P1 and P2 summation)

Load check valve

B5 A5

a5

T
Parallel passage
TS Ai

a5

T
P2

Gauge
GAUGE
P1

a9

B9

A9

a9

T
555C92MC09

2-18
· During boom up operation, the pilot pressure from RCV is supplied into the port a9 and shift the
boom 1 spool in the left direction. The hydraulic oil fluid from pump P1 is entered P1 parallel
passage and then passes through the load check valve then flows into the port A9.
Following this, it flows into the head side of the boom cylinder.
At the same time the pilot pressure through the port a5 shifts the boom 2 spool. The hydraulic oil
fluid from pump P2 is entered P2 parallel passage and then passes through the load check valve
then flows into the port A5. The flows combine in hydraulic hoses and are directed to the cylinder
head side of boom cylinder.
The flow from rod side of the boom cylinder return to the boom 1 spool through the port B9.
There after it is directed to the hydraulic oil tank through the tank passage.
· The TS signal passage oil from the Pp port is drain to the hydraulic oil tank through the left/right
travel valve and the signal pressure is not raised.
· The Ai signal passage oil from the Pp port is shut off by shifting of the boom 1 spool and then
signal pressure of auto idle is raised.

2-19
② Boom down operation

TS Ai

P1 Gauge
GAUGE

b9
Load check valve

B9 A9

b9

T
Parallel passage
555C92MC10

· During the boom lowing operation, the pilot pressure from RCV is supplied to the port b9 and
shift the boom 1 spool in the right direction.
The hydraulic fluid from the pump P1 enters the parallel passage and is directed to the port B9
through the load check valve. Following this, it flows into the rod side of the boom cylinder.
The return flow from the head side of the boom cylinder returns to the boom 1 spool through the
port A9. Thereafter it is directed to the hydraulic oil tank through tank passage.
· The hydraulic oil flow from the Pp port is same as the boom up operation.

2-20
(3) Bucket operation
① Bucket roll in operation

TS Ai

Gauge
GAUGE
P1

b10

B10 A10

b10

T
Load check valve
555C92MC11

· During the bucket roll in operation, the pilot pressure from RCV is supplied to port b10 and shift
the bucket spool in the right direction.
The hydraulic fluid from pump P1 entered P1 parallel passage and is directed to the port B10
through the load check valve.
Following this, it flows into the head side of the bucket cylinder.
The return flow from the rod side of the bucket cylinder returns to the bucket spool through the
port A10. Thereafter it is directed to the hydraulic oil tank through the tank passage.
· The TS signal passage oil from the Pp port is drain to the hydraulic oil tank through the left/right
travel valve and the signal pressure is not raised.
· The Ai signal passage oil from the Pp port is shut off by shifting of the bucket spool and then
signal pressure of auto idle is raised.

2-21
② Bucket roll out operation

TS Ai

P1 Gauge
GAUGE

a10

B10 A10

a10

555C92MC12

· In case of the bucket roll out operation, the operation is similar.

· The hydraulic oil flow from the Pp port is same as the bucket in operation.

2-22
③ Bucket load check valve operation

pp2

PLUNGER
Plunger

ORIFICE
Orifice

555C92MC13

· This function is used to speed up of the boom or arm by reducing the bucket speed when bucket
operation with boom or arm operation simultaneously.
· When the signal pressure flows into port pp2, the plunger is shifted and orifice is made.
· The hydraulic oil from the port P1 flow into bucket cylinder via the orifice and then the speed of
bucket cylinder is slow down.
Accordingly, the much fluid from the port P1 is supplied other cylinder than the bucket cylinder.

2-23
(4) Arm operation
① Arm roll in operation (P1 and P2 summation)

B6 A6

b6

T TS Ai

P2

P1 GAUGE
Gauge

b11

b11

555C92MC14

2-24
· During arm roll in operation the pilot pressure from the RCV is supplied to the port b6 and b11
and shifts arm 1 spool and arm 2 spool in the direction.
The hydraulic oil from the pump P2 flows into the arm cylinder head side through P2 parallel
passage, the load check valve and the port B6.
At same time, the hydraulic fluid from the pump P1 flows into the arm summation passage in
arm 1 spool through the arm 2 spool. Then it entered the arm cylinder head side with hydraulic
fluid from arm 1 spool.
· The TS signal passage oil from the Pp port is drain to the hydraulic oil tank through the left/right
travel valve and the signal pressure is not raised.
· The Ai signal passage oil from the Pp port is shut off by shifting of the arm spool and then signal
pressure of auto idle is raised.

2-25
② Arm roll out operation

B6 A6

a6

T TS Ai

a6

P2

P1 Gauge
GAUGE

a11

a11

555C92MC15

· During arm roll out operation the pilot pressure from RCV is supplied to the port a6 and the a11
and shifts arm 1 spool and arm 2 spool in the left direction.
The hydraulic fluid from pump P2 flows into arm 1 spool through the parallel passage. Then it
enters into the arm cylinder rod side through the load check valve and the port A6.
At same time, the hydraulic oil from the pump P1 flows into the arm summation passage in arm
1 spool through the arm 2 spool.
The return flow from the arm cylinder head side returns to the hydraulic tank through the port B6
the arm1 spool and tank passage.
· The hydraulic oil flow from the Pp port is same as the arm roll in operation.

2-26
(5) Swing operation

B1 A1

Pp
Ai

Swing
SWING
a1

P3

555C92MC16

· The pilot pressure from the RCV is supplied to the a1 and shift the swing spool in left direction.
The hydraulic fluid from pump P3 flows into swing spool through the parallel passage. Then it is
directed to swing motor through the port A1. As a result, swing motor turns and flow from the
swing motor returns to the hydraulic oil tank through the port B1, swing spool and the tank
passage.
In case of swing left operation, the operation is similar.
· The TS signal passage oil from the Pp port is drain to the hydraulic oil tank through the left/right
travel valve and the signal pressure is not raised.
· The Ai signal passage oil from the Pp port is shut off by shifting of the swing spool and then
signal pressure of auto idle is raised.

2-27
(6) Travel straight function

Parallel passage
P2 P1

Center bypass passage

Pp
Ai

Sa
P3

b7

P2

P1 Gauge
GAUGE
b8

Cut off
BOOM orwhen
ARMthe
or boom,
BUCKET
arm and bucket
CUT operation
555C92MC17

2-28
· This function keeps straight travel in case of simultaneous operation of other actuators (boom,
arm, bucket, swing, woodgrab) during a straight travel.
① During travel only :
The hydraulic fluid of the pump P1 is supplied to the travel motor and the pump P2 is supplied to
the other motor.
Thus, the machine keep travel straight.
② The other actuator operation during straight travel operation.
When the other actuator spool(s) is selected under straight travel operation, the straight travel
spool is moved.
Some of hydraulic fluid from pump P1 and P2 is supplied to the travel motors through parallel
passage and the other hydraulic fluid is supplied to the actuator(s) through center bypass
passage via orifice passage.
Thus, the machine keeps straight travel.
· The fluid flows into P3 pilot port Sa through the gauge port and the spool is shifted. As a result,
the fluid of P3 pump is combined with the boom, arm and bucket and then the actuators speed
up.

2-29
(7) Holding valve operation
① Holding operation
Actuator port Check Spring Drain port Pilot port Pilot piston chamber
A9
Dr xb9

Boom holding
valve

Boom 1 a9
spool

Plug Poppet Poppet seat Piston A Spring B Piston B

55W72MC16

At neutral condition, the pilot piston chamber is connected to drain port through the pilot port.
And the piston "B" is supported with spring "B".
Also, the pressured fluid from actuator entered to inside of the holding valve through the periphery
hole of check, crevice of the check and the plug and the periphery hole of plug.
Then, this pressured oil pushed the poppet to the poppet seat and the check to the seat of body.
So the hydraulic fluid from actuator is not escaped and the actuator is not moved.

② Release holding operation

Actuator port Check Spring Drain port Pilot port Pilot piston chamber
A9
Dr xb9

Boom holding
valve

Tank passage

Boom 1 a9
spool

Plug Poppet Poppet seat Piston A Spring B Piston B

55W72MC17

The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in
the left direction against the spring "B", and shifts the poppet in the left direction through piston "B"
and piston "A" against spring "B" and shifts the spool in the left side.
At same time, the return fluid from actuator returns to the drain port through the periphery hole of
check, crevice of the check and the plug, the periphery hole of the plug, in side of holding valve,
crevice of the poppet and the poppet seat, the periphery hole of the poppet seat, crevice of socket
and spool and internal passage of spool.
When the poppet is opened, pressure of inside of holding valve is decreased and the return fluid from
actuator returns to the tank passage through the notch of spool.

2-30
GROUP 3 SWING DEVICE

1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
1) SWING MOTOR
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.

Outlet shaft Oil level gauge Time delay valve Mu GA GB Dr

Gear oil filling port(PT1/2) SH PG A B

5592SM01

Port Port name Port size

SH
A Main port SAE PF 1/2
PG B Main port SAE PF 1/2
Dr Drain port PF 3/8
Air vent Mu Make up port PF 3/4
PG Brake release stand by port PF 1/4
SH Brake release pilot port PF 1/4
Dr
GA,GB Gauge port PF 1/4
GA GB

A Mu B

Hydraulic circuit

2-31
4 6 8 3 14 29 30 16 22 33 34 41,42 19 20,21 35 36 38 37

1 2 5 7 10 9 11 26 27 28 13 15 12 32 31 17 24 25 39 40 18

555K2SM03

1 Body 15 Taper bearing 29 O-ring

2 Oil seal 16 Valve plate 30 Spring
3 Cylinder block 17 Relief valve assy 31 Time delay valve
4 Shaft 18 Socket bolt 32 Socket bolt
5 Taper bearing 19 Plug 33 Plug
6 Bushing 20 Plug 34 O-ring
7 Shoe plate 21 O-ring 35 Valve
8 Spring 22 Shim 36 Spring
9 Set plate 23 Plug 37 Plug
10 Piston shoe assy 24 Back up ring 38 O-ring
11 Ball guide 25 O-ring 39 O-ring
12 Rear cover 26 Friction plate 40 Back up ring
13 Pin 27 Plate 41 Name plate
14 O-ring 28 Parking piston 42 Rivet

2-32
2) REDUCTION GEAR

2 3 4 5 6 31 26 28 30 29 7 8

24
32

23
22

21

9
25

1 16 15 14 13 27 20 11 17
55W72SM02

1 Shaft 12 Carrier assy 2 23 Bushing 1

2 Bearing cover 13 Dowel pin 24 Thrust washer 1
3 Taper roller bearing 14 Collar 25 Thrust washer 3
4 Case 15 Plug 26 Thrust washer 2
5 Oil seal 16 Plug 27 Carrier assy 2
6 Taper roller bearing 17 Cover 28 Planet gear 2
7 Sun gear 2 18 Pipe 29 Pin 2
8 Socket bolt 19 Level gauge 30 Bushing 2
9 Sun gear 1 20 Carrier assy 1 31 Spring pin
10 Carrier assy 1 21 Planet gear 1 32 Snap ring
11 Ring gear 22 Pin 1 33 Thrust washer 4

2-33
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(16),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(10) upon the return plate(9) which acts upon the swash plate(7) via an hydrostatic bearing.
Force F1 perpendicular to swash plate(7) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(3) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pÝq F
T= , q=ZÂAÂPCDÂtanɾ, F1 = , F2=F tanɾ , S=PCDÝtanɾ
2ӕ COSɾ



Where p : Effective difference of pressure (kgf/cm2)
q : Displacement (cc/rev)
T : Output torque (kgfÂcm)
Z : Piston number (9EA)
A : Piston area (cm2)

ɾ: Tilting angle of swash plate (degree)
S : Piston stroke (cm)

Low High
pressure oil pressure oil

F1 F1
F

16

7 9 10 3 R5572SF35

2-34
2) MAKE UP VALVE
(1) Outline
The safety valve portion consists of a
check valve and safety valve.
(2) Function
When the swing is stopped, the output
circuit of the motor continues to rotate
because of inertia. For this reason, the
pressure at the output side of the motor
becomes abnormality high, and this will
damage the motor. To prevent this, the oil
causing the abnormal hydraulic pressure
Dr
is allowed to escape from the outlet port
(high-pressure side) of the motor to port
Mu, thereby preventing damage to the
motor. A Mu B
Compared with a counterbalance valve,
there is no closed-in pressure generated
at the outlet port side when slowing down
the swing speed. This means that there is
no vibration when slowing down, so the 555C92SF36

ease of swing control is improved.

(3) Operation
Η When starting swing
When the swing control lever is operated
to left swing, the pressurized oil from the
pump passes through the control valves
and is supplied to port B. Because of
this, the pressure at port B rises, staring
torque is generated in the motor, and the
motor starts to rotate. The oil from the
outlet port of the motor passes from port
A through the control valve and returns to
the tank.

2-35
Θ When stopping swing
 When the swing control lever is returned
to neutral, no pressurized oil is supplied
from the pump to port B.
The return circuit to the tank is closed by SH
the control valve. So the oil from the
outlet port of the motor increases in PG
pressure at port A. Resistance to the
rotation of the motor is created, and the
brake starts to act.
 The pressure at port A rises to the set
pressure of make up valve a, and in this
way, a high brake torque acts on the Dr
motor, and the motor stops. GA GB
 When make up valve a is being actuated,
the relief oil from make up valve a and A Mu B
the oil from port Mu pass through check
valve CB and are supplied to port B.
This prevents cavitation from forming at
R5572SF32
port B.

2-36
3) RELIEF VALVE

2 1 Body
2 Plug
3
3 O-ring
4 Plunger
10 5 Piston
6 Spring
5 7 Spring seat
8 Seat
9 O-ring
9 10 Nut

8
555C92SF37

(1) Construction of relief valve

The valve casing contains two cartridge type relief valves that stop the regular and reverse
rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing
motion and can control the relief pressure in two steps, high and low, in order to insure smooth
operation.

(2) Function of relief valve

Figure illustrates how the pressure acting P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3

T
1
29072SM05

2-37
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.

Work Deceleration Stop

A B A B A B

MCV MCV MCV

MCV A, B opened MCV A, B throttled MCV A, B closed

210-7 2-48(1)

(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work
can be done more easily and safely.

Η Brake assembly
Circumferential rotation of separate plate
(27) is constrained by the groove located
at casing (1). When housing is pressed
down by brake spring (30) through
friction plate (26), separate plate (27)
and brake piston (28), friction force 30
occurs there.
Cylinder (3) is constrained by this friction 28
force and brake acts, while brake 27
releases when hydraulic force exceeds
26
spring force.
3
1 R5572SF38

1 Casing 27 Separate plate

3 Cylinder 28 Brake piston
26 Friction plate 30 Brake spring

2-38
Θ Operating principle
a. When the swing control lever (1) is set to the swing position, the pilot oil go to the swing control
valve (2) and to SH of the time delay valve (3) via the shuttle valve (4), this pressure move
spool (5) to the leftward against the force of the spring (8), so pilot pump charged oil (P4) goes
to the chamber G.
This pressure is applied to move the piston (28) to the upward against the force of the spring
(30). Thus, it releases the brake force.

3
30

5
28 G
SH

1 Swing control lever

2 Swing control valve (MCV)
3 Time delay valve
12
4 Shuttle valve
5 Spool P4
8 Spring
12 Gear pump
2 2
28 Brake piston
30 Brake spring 4
R5572SF39

2-39
b. When the swing control lever (1) is set the neutral position, the time delay valve (3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston (28) is moved lower by spring (30) force and the return oil from the chamber G
is drain.

3
30

28 G
SH

1 Swing control lever

2 Swing control valve (MCV)
3 Time delay valve
4 Shuttle valve
28 Brake piston
30 Brake spring P4

2 2
4
R5572SF40

2-40
 GROUP 4 TRAVEL DEVICE

1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.

A Travel motor Reduction gear Supply port PT 3/8

FILL

LEVEL

a2 a1

DRAIN

Check port PT 3/8 Drain port PT 3/8

Ps

P2 P1
T2 T1

VIEW A

5592TM01

10 36 83

Port Port name Port size

17 33 83

P1 Main port PF 1/2

T2 T1
a1
P2 Main port PF 1/2
a2
a1,a2 Gauge port PT 1/4
PS
T1,T2 Drain port PF 3/8
Ps 2 speed control port PF 1/4

P2 P1

Hydraulic circuit

2-41
1) BASIC STRUCTURE

Reduction gear

Hydraulic motor
Brake valve
Parking brake
High/low speed
changeover
mechanism

Control valve

Pump

5592TM02

2-42
2) STRUCTURE

86 85
36 37 39,40 38 58 28 29 30 31 56 57 24 23 22 21 20 19 18 17 10 9 16 4 8 64 1 5 59 82 83

69

70
73
72
52,53 87,88 71
54

A A 79

78

80
47 48 50 51 49
74
75
81
77
A-A

55 84 26 41 42 46 45 43 44 32 33 24 34 27 35 25 14,13,12,11 63 15 60 62 61 6,7 2 65 3 67 68 66 76

555K2TM03

1 Shaft casing 16 Ball guide 31 Snap ring 46 Relief valve assy 61 Steel ball 76 Planetary gear
2 Expand 17 Set plate 32 Check 47 Steel ball 62 Plug 77 Needle bearing
3 Oil seal 18 Piston kit 33 Spring 48 Check seat 63 Floating seal 78 Drive gear
4 Shaft 19 Friction plate 34 Seat 49 Plug 64 Nut 79 Thrust plate
5 Bearing 20 Parking plate 35 Snap ring 50 Plug 65 Washer 80 Ring gear cover
6 Swash piston kit 21 Parking piston 36 Check 51 O-ring 66 Collar 81 Plug
7 Spring 22 O-ring 37 Spring 52 Plug 67 Planetary gear 82 O-ring
8 Swash steel ball 23 O-ring 38 Plug 53 O-ring 68 Needle bearing 83 Wrench bolt
9 Swash plate 24 O-ring 39 O-ring 54 Ball bearing 69 Plate 84 Orifice
10 Shoe plate 25 O-ring 40 Back up ring 55 Pin 70 Bolt 85 Back up ring
11 Cylinder block 26 Rear cover 41 Main spool kit 56 Valve plate 71 Sun gear 86 Back up ring
12 Spring seat 27 Plug 42 Spring seat 57 Spring plate 72 Snap ring 87 Name plate
13 Spring 28 Spool 43 Spring 58 Wrench bolt 73 Carrier 88 Rivet
14 Snap ring 29 Spring 44 Plug 59 Ring gear 74 Spring pin
15 Pin 30 Stopper 45 O-ring 60 Angular bearing 75 Collar

2-43
2. PRINCIPLE OF DRIVING
1) GENERATING THE TURNING FORCE
The high hydraulic supplied from a hydraulic pump flows into a cylinder (11) through valve casing of
motor (26), and valve plate (56).
The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower
sides of piston (18).
The high hydraulic can generate the force, F1 = PÝA (P : Supplied pressure, A : water pressure
area), like following pictures, working on a piston.
This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the
swash plate (9) of a tilt angle, ɷ.
W1 generates torque, T = W1+R1, for Y-Y line connected by the upper and lower sides of piston as
following pictures.
The sum of torque (ɨW1ÝR1), generated from each piston (4~5pieces) on the side of a high
hydraulic, generates the turning force.
This torque transfers the turning force to a cylinder (11) through a piston; because a cylinder is
combined with a turning axis and spline, a turning axis rotates and a turning force is sent.

Y
Cylinder A Piston

W1
R1 W1
N1
f1 P
0 F1

Drive shaft

High Low
pressure pressure
Y

5592TM03

2-44
2) WORKING OF RELIEF VALVE
Relief valve carries on two functions of followings.
(1) It standardizes a pressure in case of driving a hydraulic motor ; bypasses and extra oil in a motor
inlet related to acceleration of an inertia to an outlet.
(2) In case of an inertia stopped, it forces an equipment stopped, according to generating the
pressure of a brake on the projected side.
Room A is always connected with port A of a motor. If the pressure of port is increased, press
poppet B. And if it is higher than the setting pressure of a spring, the oil of an hydraulic flows from
room A to port B, because poppet A is detached from the contact surface of seat A.

11 12 10 5 9 13 14 15 18 1 17

Port A Port B

Room A Seat A Poppet A 8 7 6 3 4 2 16

5592TM04

2-45
3) WORKING OF BRAKE
Brake operates the pressure supplied through SPOOL (simultaneous peripheral operation online)
installed in valve casing (26) to the part of parking piston (21) and releases a brake.
When the pressure does not work, the brake always runs.
The force of a brake is generated by the frictional force among a plate (20), brake piston (21) and a
cylinder block (11) that is connected through spline which are fixed by shaft casing (1) with friction
plate (19).
When a pressure does not work on the part of piston, brake spring presses brake piston; oil in a
brake room flows into the drain of a motor through an orifice; in that time, brake piston compresses
a frictional plate (19) and a detached plate in the middle of shaft casing and brake piston according
to the force plate springs (57); finally, it makes a frictional force.
This frictional force helps the brake fixing a turning axis (3) connected by a cylinder and spline
operated.

57 18 21 20 19 1 11 4

555K2TM06

2-46
4) COUNTERBALANCE VALVE
Av port is connected into a hydraulic pump and Bv port is into a tank. Hydraulic pump supplying oil
is come into Av Ą Cv room. In accordance with spring force (43) that is working on the spool's
side it moves to the spool (41) on the right side which is medium position and that time motor is
turning.
When the spool (41) is come back to the medium position that time hydraulic motor is stopped.
In accordance with spool's returning speed and shape control the working oil that is returning from
hydraulic motor smoothly stopping the motor.

Av Bv

Cv

84 41 42 45 43 44

555K2TM07

2-47
4) HIGH/LOW SPEED CHANGEOVER MECHANISM
(1) At low speed-at pilot pressure of less than 10 kgf/cm2 (0.98 Mpa
Mpa)

A 28 29 9 Holder flange

B q1

Spring

Case of motor
C

5592TM05

When no pilot pressure is supplied from port (A) at a pressure of 10 kgf/cm2 (0.98 Mpa) or less,
spool (28) is pressed toward the left by the force of spring (29), the pressurized oil supply port B is
shut off, and oil in chamber (C) is released into the motor case via spool (28).
Consequently, swash plate (9) is tilted at a maximum angle (ɾ1°) and the piston displacement of
hydraulic motor becomes maximum, thus leading to low-speed rotation.

(2) At high speed-at pilot pressure of 10 kgf/cm2 (0.98 Mpa

Mpa)) or more

A 28 29 9 Holder flange

b
B
q1

Spring

Case of motor
C

6
5592TM06

When a pilot pressure is supplied from port (A) at a pressure of 10 kgf/cm2 (0.98 Mpa) or more, the
pressure overcomes the force of spring (29) and spool (28) is pressed toward the right. The
pressurized oil at supply port (B) is then introduced into chamber (C) via spool (28).
Piston (6) pushes up swash plate (9) until it touches side (b) of the holder flange.
At this time, swash plate (9) is tilted at a minimum angle (ɾ2°) and the piston displacement of
hydraulic motor becomes maximum, thus leading to high-speed rotation.

2-48
2. REDUCTION GEAR
1) FUNCTION
The reduction gear unit consists of a combination of simple planetaly gear mechanism.
This mechanism reduce the high speed rotation from the hydraulic motor and convert it into low
speed, high torque to rotate the hub (or case), which in turn rotates the sprocket.
2) OPERATING PRINCIPLE
Shaft Ą Drive gear Ą Planetary Gear R Ą Housing
Ą Holder Ą Sun gear Ą Planetary Gear F ĄRotation of Housing

Holder flange Shaft

Planetary gear(F)

Planetary gear(R)

Drive gear

Holder
Holder flange Sun gear Housing

5592TM07

Reduction ratio = (Housing Teeth/Drive Gear Teeth + 1)

Ý(Housing Teeth/Sun Gear Teeth + 1) - 1.

2-49
GROUP 5 RCV LEVER

1. STRUCTURE
The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the
secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face.

23.3 Switches
No. LH RH
5 One touch decel Horn
6 - Breaker
5

B
6
19
25
Single
operation Simultaneous
operation DETAIL B

Tilted direction of
handle(RH)

1 P

T Tilted direction of
connector(LH, RH)
2 3

Tilted direction of
handle(LH)

VIEW A

21092RL01

A
Port LH RH Port size

P P Pilot oil inlet port Pilot oil inlet port

T
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
2 Arm in port Boom down port
3 Right swing port Bucket in port
4 Arm out port Boom up port
1 3 2 4
Hydraulic circuit

2-50
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool (4), spring (6) for setting secondary pres-
sure, return spring (10), stopper (8), spring seat (7, 13) and shim (5). The spring for setting the sec-
ondary pressure has been generally so preset that the secondary pressure is 5 to 20.5 kgf/cm2
(depending on the type). The spool is pushed against the push rod (9, 11) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.

2-51
 CROSS SECTION

23
25

26

24

22

21
9
19
20 16
17
18
14
11 15
8
7
27 10
6
13
5
12
4

3
1
2
Port 1,3 Port 2,4
21092RL02

1 Case 8 Stopper 15 O-ring 22 Lock nut

2 Plug 9 Push rod 16 Rod seal 23 Handle assembly
3 Bushing 10 Spring 17 Plate 24 Handle bar
4 Spool 11 Push rod 18 Boot 25 Nut
5 Shim 12 Spring 19 Joint assembly 26 Boot
6 Spring 13 Spring seat 20 Swash plate 27 Bushing
7 Spring seat 14 Plug 21 Adjusting nut

2-52
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and apply-
ing the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following ele-
ments.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (4) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring (6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (9,11) is inserted and can slide in the plug
(14).
For the purpose of changing the displacement of the push rod through the swash plate (20) and
adjusting nut (21) are provided the handle (23) that can be tilted in any direction around the fulcrum
of the universal joint (19) center.
The spring (10) works on the case (1) and spring seat (7, 13) and tries to return the push rod
(9,11) to the zero-displacement position irrespective of the output pressure, securing its resetting to
the center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.

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3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.

5 6

3
1
3
P T

2 4

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1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

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(1) Case where handle is in neutral position

10

T 6

P
4

1 3

21092RL03

The force of the spring (6) that determines the output pressure of the pilot valve is not applied to
the spool (4). Therefore, the spool is pushed up by the spring (10) to the position of port (1, 3) in
the operation explanation drawing. Then, since the output port is connected to tank port T only,
the output port pressure becomes equal to tank pressure.

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(2) Case where handle is tilted

11

1 3

21092RL04

When the push rod (11) is stroked, the spool (4) moves downwards.
Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port
(1) to generate the pressure.
When the pressure at port (1) increases to the value corresponding to the spring force set by tilt-
ing the handle, the hydraulic pressure force balances with the spring force. If the pressure at port
(1) increases higher than the set pressure, port P is disconnected from port (1) and port T is con-
nected with port (1). If it decreases lower than the set pressure, port P is connected with port (1)
and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be con-
nected with port P.

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